Method and apparatus for forging crankcases



vMany 14, 194.6. c. A. BRAUCHLER METHOD AND APPARATUS FOR FORGING CRANKCASES 6 Sheets-Sheet 2 YFiled July l, 1945 May 14,1946. Q A, BRAUCHLER 2,400,387

n METHOD AND APPARATUS FOR' FORGING CRANKCASES Filed; July 1, 1943 V- e sheets-'sheet s Maly 14,1946. c. A. BRAUCHLER- METHOD AND APPARATUS FOR FORGING CRANKGASES 6 Sheets-Sheet 4 Filed July l, 1945 May14, 1946. c. A. BRAUCHLER METHOD AND APPARATUS FOR FOGING CRANKCASES- 6 Sheets-Sheet- 5 Filed .July 1, 1943 y *www c/mfwsmaaw- May 14, 1946.

'C. A. BRAUCHLER METHOD AND APPARATUS FOR FORGING CRANKCASS 6 Sheeis-Sheet 6 Filed July I1. 1943 Patented May 14, 1946 i v MErnoniYANDQAPPARATUsFoaFORGING 1 `ClwnvlroAsnsI A' Charles A. Brauchler; Canton, Ohio i Applieaubn July1,c1943, serial No. 493,025. c

-K 9 Claims; (Cl. :ze- 15am The invention relates to; the ,producztionl :of forgings for the crankcases of radialmotors such as areused in aircraft, and *.moreiparticularlys:

to means whereby better forgingsrnay beA produced with less labor, time. and eXpense-than-lum der present practice. y v l 7 Cra-nkcases ofV thisfcharaoter are formed of mating sections, eachfoffwhichis of generally circular shape having, a lcentral openinglA Shaped.-

to receive a bearing for the crankshafgjand pro- "forging, dimensions with;V the ,peripheral `flangeexvided with arrannul'ar z peripheralrrjiiange having Y spaced, halffrurld Cutmitsfwithinturnedglues the edge of theangebetweensaid cutouts. sections of :this general-1 typemare opposed and attached Vtogether by boltsjo-r the like located for easily and readily disengaging lthe 'formed crankcase forging from the bending dies.

Still another object is the provisionv of means Y cornprising a slidable vring surrounding one ofthe bendngtdiesand va.plunger.operated spider for moving the `lying longitudinally upon thefdie to straighten and line-up,theinturned` lugs upon the peri-plierall flange ofthe forging.

The "above and other objects are attained by forging thecrankcase section to the specified tending outitfa'rd; around thel periphery of the forgingy in substantially flat condition,` and the lugs at the-fedgeof thesfiange. extending downthrough the abutting inturned, lugstlfie/gcorre- 'Y sponding half-roundcutout portions of, the-itwou. Y

sections forming circulargyopenirrgs whiolr-receiveV ,the mater-- the radially disposed cylinders of v, simsi; :are

Undef., presen@ Practice forged withrtheperipheral fia-ngepf': afthikness i equal vto the length of Y.thefinturnedflugsfat the,v

edge of the 'nange after which Iitfis necessary-1i l for the flange to be. machined downtoa specifi d thickness before the forgings are delivered vbyfthe f drop farginglplantto the airplanelengrinefmanufacturer.

This machi the grain flow ofl the:V metal, leaving a cross-ggrainninggwork at fthe-drop :forging plane Y not only requires many hoursofylaboribut a con-` Sider-able amount'of excess metal in ther-forging is 'out awayand this Vmachiningcutis through in the inturned lugs at the ,edges of thefflanga thus obviously weakening the structure .atthese points. Y

Igt is an object-of the present inventionto over-l come thesefobiectsby providing a method and means for producing such crankcase forgings'q withoutthe use of any excess metal,y thus obviating the necessity of machine work at the drop forging plant, andY at thesaxne'time producing a stronger and better structure. in ,which .the grain .with'the' tudinally'through the'i'nturnedlugs'.

n Anernbodimentof the invention is illustratedin ,the'accornpanyi'ng drawings' in whichward; and then'fbending vthe .peripl'ieral 'flange downwaidt'o therequired position With thelugs at Vvtlnefe'dge thereof turned inward sothat the finished forging .is Produced Awith'c` 1.1t requiring any' machineworkat the-drop forgingA plant and gra'inflow ofthe metal extending longijf.v

v1*"igure .1 isa topplan view of one motor Ycrankcase,section; i Fig. 2, a` transverse lsection taken on fthe line 2-,..,Z, 1i"ig.v l; Y

`3, ajvertcal sectional viewofthe forging dies, forf producing the initial, substantially flat forging, showingthe dies in closed positionY with the initial crankcase section forging therein.;-r

lFig. 4, a transverse sectional view through the form of radial initial forging produced by 'thedies shown in Fig. 3; Y

y l vertical; sectional view throughthe bending; diesfshowing the dies in openposition ywith the vinitial forging positioned'A therein before bending; y

Fig. 6, a view'similar tor Fig. 5 showing` the bending dies in closed positionwith the finished Y Y crankcase section vforging therein;

flow in the metalY -is'arranged longitudinally 1 i through the y inturned lugs. at thefedges of,. the

peripheral nange.

Another object is the i by the crankcase section is forgedy in substantially provisionof means where- 4 rvFigL'T, abottomplanlsectional view of the lower bending dies and the slidable ringand spider for iiattening and lining-.up the inturned lugs taken -on thelin'e '1 -i1, Fig', 6;".V i i. if

Fig. 8,' a top plan view of kone--lialfof the lower bending die;

flat condition and then while hot'placed in bend- Y.

ing dies which bend'thefperipheral ange down to the desired position'.r y

Ai further object is the yprovisionof means assolciatedwith the bending dies for straightening and lining-up all of the inturned lugs at Vthe Aedge Y of the peripheral flange.

A still further object is the 'provision of means f Fig. 9, a fragmentary full size `sectional view through the peripheral flangeportion of the kcrankcase section as forged under presentpracand' shape; and

Fig., 11, a similar view ofthe peripheral iiange Athe same v"'sirrliilar view.V afterv the peripheral y flange has been machined to the specified@size y to similar parts One form of crankcase section of this general type is illustrated and described herein asP illustrative of the manner in which the invention may be practiced to produce anyof the various section is initially forged from a block or blank of steel or the like, in` dies as shown in Fig. 3 in which the lower forging die 22 may be xed upon the bottom of a drop hammer and the upper die 23 may be carried by the ram or head 24 of the hammer.

These forging dies have the complemental recesses 25 shaped to produce the initial forged product I5 having the central opening IIi surrounded by the bearing receiving portion I'I, as in the .finished forging, the peripheral flange IBC with cutout portions I9c being extended outward substantiallyin the plane of the body portion of the forging, the flange being ofthe thickness designs f crankcase sections for radial motors,

and it should be understood that the invention applies to all designs of such crankcase sections having the common characteristics above re ferred to.

The airplane v:motor manufacturer furnishes the drop forging plant with the specifications and dimensions of the crankcase forging to be produced bythe forging plant, and as above mentioned under present practice it is necessary for the forging plant to do considerable machine VVwork upon the forging in order to meet the specifications of the motor manufacturer.

In Figs. land 2 is illustrated a typical designl of a crankcase forging of the general type referred to showing the saine in the condition specified by the airplane motor manufacturer.

This crankcase section is indicated generally at I having the central opening I6 surrounded by a bearing receiving portion Il and provided with the downv` turned peripheral flange` I8, having half-roundcutouts I9 therein, the flangeV I8 terminatingY in inturned lugs 2,0 between said'l cutouts.

Under present f practice it is not possible to forge the flange I8 Vto the desired dimensions with the inturned Vlug Il at its end but this ange is forged of a thickness equal to the length of the lug as indicated at I8?l in Figure 9,

The inner side of this flange is then machined out as indicatfad at A2I in Figure 10, leaving the flange I 8b of the required thickness and the inturned lug 2lia at the edge of the flange. This machine work requires considerable labor and expense and a great deal of excess metal' which has been forged into the flange is cut away.

This costly operation is necessary. however under' present practiceusince there is no other known way to forge such parts to the required size and shape.

The present invention overcomes the above objections` and eliminates the time, labor and expense required for machiningv the `peripheral fiangeasshown inA Fig.' 10 and also produces the forging. of specified size and shape withouttany excess metal therein.

Briefly the invention consists in initially forging the crankcase section in substantially flat condition with the'peripheral flange extended out substantially in the normal planel of the body portion of the forging, said flange being forged to the required thickness with the lugs formed at the edge of the flange.

Then in a bending operation the flange is bent to the. desired position and the crankcase section forging is ready for delivery to the airplane engine manufacturer.

In carrying out the invention the crankcase desired in the finished forging and being provided at its edge with the down turned lugs 20".

The initial forging thus produced is shown in Fig. 4 as it appears when removed from the forging. die. This initial forging is then placed in bending dies shown in Figures 5 to 8 inclusive where the n'al'operation is performed.

These' bending dies comprise the lower fixed die 26, which is fixed to the bed 2l 0f a press, and the upper movable die 28 which is carried by the ram or head 29 of the press. u 'f `The lower die 26 may be attached to the bed 21 bymeans ofa plate 33 connected to the bottom of the die as by screws 3| and connected to the bed 21 as by the screwsor bolts 32.

'I'he underside of the lower die 26 is provided with a cross shape groove 33 within which is mounted, for"vertical movement,l a cross shape spider 34 which normally rest-s upon thel bed plate 30 as shown in Figure 5. VAs this spider is of a thickness somewhat less than the k depth nf the groove 33, as shown quite clearly in'Figures '5 and 6, the spider ls permitted to have a limited vertical movement between the top of the groove 33 and the base plate 30; l

fA` ring 35 is slidably mountedaround the lower, cylindric portion of theflower die '25 andv rests upon the outer endvportionV of the lugs of th'e spider 34 which protrude `considerably beyond the periphery of the die 26 as shown inFigs. 5, 6

l and '7. f

VA plunger-36, which may be operated by the 2, the periphery of the die being vvreduced below said portion 3B,v forminga peripheral recess as at 40 to receive the inturnedlugs 2li. Af.

The Vupper movable die 23 is shaped on' its underside to conform tothe upper contour of the body portion of the initial forging yas shown at Y 4I and is provided around its 'periphery with the depending skirt 42 shaped to conform to the outer contour of the flange I8.

The heated initial forging I5a is placed upon,

the lower die 26 as shown in Fig. 5. and the upper die 28 is'then lowered by the ram or head29 of the press, as shown in Fig. 6, bending the flange I8 Vdown vas shown in said lfigure, the inturned lugs 20 thereon beingreceivedr in the recess 40 of the lower die.

In order to Yproperly straighten and line-up all of the lugs 20 in the same plane, the plunger 36 is then operated-raising the spider 34 andring 35, asi shown' in Fig. y6, the upperfsurfaceVV of Vthe ring engaging the undersurfaces of "the: lugs flattening the samevandlining'them; alli up properly in 4thesame plane;

register with theperipheral notches-lpermiti' ting the forging to be raised from the lowerfdie. The finished forging rthus produced is shown in Figs. 1 and 2 and is readyfor delivery tov th'eengine'manufacturer without'frequiring any ina-'- chine work at the drop' forging plant.

Y Thus with the combinedV forging andY bending operations the finished forging is produced not only eliminating 4the time, vlabor and 'expense of machine work at the forge shopin cutting away excess metal but a :str'ongeifandbet'ter forging is produced as the. arrangement'f'of the grain llowthrough the flange ISVandv inturnedflugs 2!!` is superior to that4 obtained by'presentpractice. "Referring to Figs. 9, lfand ll it'willbe seen dinally through the forged thickfflange Isa; from top to bottom thereof, and when the'e:cessjmi'etal'l is out from the inside ofv said flange, as indicated at 2| in Fig. 10,l Vthis cutsjthrough' thejgrain of the metal leaving a cross grainv through thej inturned lug 20a, thus weakening "the structure at these lugs by means 'ofwhich the cranlcase sections are connected together. Y

As shown in Eig, 1l by forging the` flange-'I8 and lug 2B to final dimensions inthe initial forging operation the grain flow of the metal will Aex-v tend down through the flangeV I8 and outward through the inturned lugs 20 thus producing a stronger and better structure.

I claim: l

1. The method of forming a forging for a crankcase section for a radial motor, said forging having a substantially flat, circular body portion provided with a central opening `surrounded by a bearing portion and a peripheral flange upon the body portion having spaced cutout portions and inturned lugs at the edge of the peripheral flange between saidcutout portions, said method consisting in forging the f article to the desired dimensions with the peripheral flange extending outward substantially in the plane of the body portion and vthe lugs yextending downward from the edge of the peripheral flange, then placing the forging while at forging temperature in bending dies and pressing the dies together bending said peripheral flange downward from the periphery of the body portion and over the peripheral portion of Vone die with the lugs extending inwardly from the edge of the flange and into under'surfaces offthe heatedv'li'igs to flattenlv them: 'and then )rotating the forgingupon said one Vdie until said lugs register with notches-'inl 15y i;

. the forging down yaround kthe peripheral portion l vof the fixed die and ypositioning the lugs in said a recess below said peripheral portion of said one die and then pressing the undersurfaces ofl the heated lugs to flatten vthem and line them up.Y

uniformly in the same plane.

2, The method of forming a forging for a cranlzcase section for a radial motor, said forging having a substantially flat, circular body portion provided with a central opening surrounded by a bearing portion and a peripheral flange upon the body portion having spaced cutout portions and inturned lugs at the edge of the peripheral flange between said cutoutV portions, said method consisting in forging the article to the desired dimensions. with the flange extendin bending dies` and pressingA the dies 'together bending said peripheralfflange downward from the periphery-of the body' portion and over the peripheral portion of fone sie with the lugs-*exif tendi'ng---inwardlyffroni 'the edge t'of the priph-f era flange and intova'recessfbelow said peripliiy era-l' fportioniof' said' one die then pressing the thefperipheral portion of said one die.v

3. rThe method. of forming a forging `forfaf crankcase,A section .for a .radialinotoig said ,forgiifg having a'.sub sftantiallyf,flat,A circularfbody portionA provided witlfi'j'a'V cntraropening Vsurf4 rounded by a.'bearingportion and a peripheral, flange upon the bodyportion having spaced. cut-,- out portions and inturned lugs at the edge' ofjthef peripheralflange betweenA said cutoutL portions', said' methodponsisung miv forging thev artigli-td the desired dimensions withlth'e peripheral: flange extending outward substantially in, the.V plane lof the' body. portionfind the lugse'xtend-- ingdownward from 'the edge of the peripheral l flange, ythen .placingthe forgingwhilefat ing temperature' inbending dies pressing the dies'together bending said., peripheral flangev downward fromfr the periphery ofiYthg-bodygpor-g tionland over Lthe peripheral portion of. oneV die,fr with the lugs extending inwardly from thefedgei Aof the peripheraliiange and into a recessbelow said peripheral portion-ofv saidy V"one dieJ-f ythenfv pressing g theY 4undersurjfaces gof, the. lugs,- ;While: heated to u flatten' them 'Y andi line Y them up uniformly lin the same plane vand then rotating the forging uponVv said one die until said lugs register with notchesl in the peripheral portion of said one die.

4. Bending and forming dies for bending a substantially flat Vcrankcase section forging tofinishedj shape, said dies comprising a fixed die" having its upper side shaped to conform to the under side of the body portion of the forging and having its peripheral portion shaped to conform tothe desiredv finished inside contour of the peripheral portion of the forging said die being peripherally recessedV beneath said peripheral portion tov receive spaced angularlugs at the periphery of the forging and a cup shaped movable die for bending the peripheral portion of recessed portion of the fixed .die and movable means upon the Vfixed die for contacting the under surfaces of the lugs.r

5. Bending and forming dies for bending a substantially nat crankcase section forging to finished shape, said dies comprising a fixed die having vits upper side shaped to conform tothe under side of the body portion of the forging and having ,itsV peripheral 'portion shaped to conform to the Vdesired finished inside contour of rthe peripheral portion of the forging said die being recessed beneath said peripheral portion to receive spaced angular lugs at the periphery of the forging, means. for bending the peripheral porf tion of the `forging down around the peripheral slidably mounted upon the Yrecessed portion ofVV ing outward .substantially in the. plane of the body portionf and the "lugs: extending, downwardA fronr'the 'edge of.` theAl peripheral flange, fthen placing the forging while atforg'ing temperature against the under surfaces of the lugs.

6. Bending and forming dies for bending a substantially fiat crankcase section forging to finished shape, said dies comprising a fixed die having its upper side shaped to conform to the under side of the body portion-of the forging and having peripheral portions at spaced locations shaped to conform to the desired finished inside contour of the peripheral portion of the-forging, said die being recessed beneath said peripheral portion to receive spaced angular lugs at the periphery of the forging, the peripheral portion of the fixed die having a plurality of spaced notches therein of greater width than the lugs said notches being located between said shaped portions. Y v

'7. Bending and forming dies for bending a substantially flat crankoas'e section forging to finishedshape, said dies comprising a fixed die having its upper side shaped to conform to the under side of the body portion of the forging and having peripheral portions at spaced locations shaped to conform to the desired finished inside contour of the peripheral portion of the forging, said die being recessed beneath said peripheral portion to receive spaced angular lugs at the periphery of the forging, the peripheral portion of the fixed die having a plurality of spaced notches therein of greater width than the lugs said notches being located between said shaped portions, a ring slidably mounted upon the recessed portion of the flxed die and means for moving the ring against the under surfaces of the lugs.

8. Bending and forming dies for bending a substantially fiat crankcase section forging to finished shape, said dies comprising a fixed die having its upper side shaped to conform to the 2,400,387. the fixed die and means lfor moving the ring' under side of the body portion of theforging and having its peripheral portion shaped to conform to the desired finished inside contour of the peripheral portion of the forging, said die bee ing reduced to form an annular recess beneath said peripheral portion to receive spaced angular lugs yat the periphery of the forging, means for bending the peripheral portion of the forging down around theperipheral'portion of the fixed die and' `positioning the lugs in said recessed portion of the fixed die, thelower end of the xed die having a groove therein, a spider vertically movable in said groove, a plunger for moving the spider in the groove and a ring resting upon the spider and surrounding the reduced portion of the fixed die for contact with the undersurfaces of the lugs.

9. Bending and forming dies for bending a substantially fiat vcrankcase section forging to finished shape, said dies comprising a fixed die having its upper side shaped to conform to the under side of the body portion of the forging and having peripheral portions at spaced locations shaped to conform to the desired finished inside contour of the peripheral portion of the forging, said die being reduced beneath said peripheral portion to receive spaced angular lugs at the periphery of the forging, the peripheral portion of the fixed die having a plurality of spaced notches therein of greater width than the lugs said notches being located between said shaped portions, the lower end of the xed die having a, groove therein, a spider vertically movablel in said groove, a plunger for moving the spider in the groove and va ring resting upon the spider and surrounding the reduced portion of the fixed die 'for contact with the undersurfaces of the lugs.

CHARLES A. BRAUCHLER. 

